Intermetallic metallic composite, method of manufacture thereof and articles comprising the same

ABSTRACT

Disclosed herein is an article comprising a plurality of domains fused together; wherein the domains comprise a core comprising a first metal; and a first layer disposed upon the core; the first layer comprising a second metal; the first metal being chemically different the second metal. Disclosed herein too is a method comprising rolling a sheet in a roll mill; the sheet comprising a first metal and having disposed upon each opposing face of the sheet a first layer that comprises a second metal; the second metal being chemically different from the first metal; cutting the sheet into a plurality of sheets; stacking the plurality of sheets; and rolling the stacked sheets in the roll mill to form a blank.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application that claims priority to aU.S. Non-Provisional application having Ser. No. 13/189,150, filed onJul. 22, 2011, the entire contents of which are hereby incorporated byreference.

BACKGROUND 1. Field of the Invention

This disclosure relates to intermetallic metallic composites, methods ofmanufacture thereof and articles comprising the same.

2. Description of the Related Art

In performing underground operations such as, for example oil andnatural gas exploration, carbon dioxide sequestration, exploration andmining for minerals such as iron, uranium, and the like, exploration forwater, and the like, it is often desirable to first drill a boreholethat penetrates into the formation.

Once a borehole has been drilled, it is desirable for the borehole to becompleted before minerals, hydrocarbons, and the like can be extractedfrom it. A completion involves the design, selection, and installationof equipment and materials in or around the borehole for conveying,pumping, or controlling the production or injection of fluids into theborehole. After the borehole has been completed, the extraction ofminerals, oil and gas, or water can begin.

Sealing systems, such as packers, are commonly deployed in a borehole ascompletion equipment. Packers are often used to isolate portions of aborehole from one another. For example, packers are used to seal theannulus between a tubing string and a wall (in the case of uncased oropen hole) or casing (in the case of cased hole) of the borehole,isolating the portion of the borehole uphole of the packer from theportion of the borehole downhole of the packer.

Sealing systems that isolate one portion of the borehole from anotherportion of the borehole generally employ an expandable component and asupport member. The support member protects the expandable componentuntil the expandable component is expanded in the borehole to effect theisolation. In order to expand the expandable component, it is desirableto first remove the support member. Removing the support member at thewrong rate can result in improper isolation of one part of the boreholefrom another. It is therefore desirable to use a support member that canbe removed in a controlled fashion when desired.

SUMMARY

Disclosed herein is an article comprising a plurality of domains fusedtogether; wherein the domains comprise a core comprising a first metal;and a first layer disposed upon the core; the first layer comprising asecond metal; the first metal being chemically different the secondmetal; the article being used as a supporting element in a sealablesystem for oil exploration.

Disclosed herein too is an article comprising a plurality of domainsfused together; wherein the domains comprise an intermetallic finegrained alloy that comprises a first metal and a second metal; whereinthe domains comprise a gradient in composition between the first metaland the second metal; and wherein the first metal is chemicallydifferent the second metal.

Disclosed herein too is a method comprising rolling a sheet in a rollmill; the sheet comprising a first metal and having disposed upon eachopposing face of the sheet a first layer that comprises a second metal;the second metal being chemically different from the first metal;cutting the sheet into a plurality of sheets; stacking the plurality ofsheets; and rolling the stacked sheets in the roll mill to form a blank.

Disclosed herein too is a method comprising disposing upon a tubestring, a sealing system; the sealing system comprising a expandablecomponent and a support member; wherein the support member comprises aplurality of domains fused together; wherein the domains comprise a corecomprising a first metal; and a first layer disposed upon the core; thefirst layer comprising a second metal; the first metal being chemicallydifferent the second metal; introducing the tube string into a well; anddissolving the support member.

BRIEF DESCRIPTION OF THE FIGURES

For detailed understanding of the present disclosure, references shouldbe made to the following detailed description of the preferredembodiment, taken in conjunction with the accompanying drawings, inwhich like elements have been given like numerals and wherein:

FIG. 1 is a depiction of an exemplary prior art sealing system; and

FIG. 2 is a depiction of an exemplary microstructure that is present inthe article.

DETAILED DESCRIPTION

The invention now will be described more fully hereinafter withreference to the accompanying drawings, in which various embodiments areshown. This invention may, however, be embodied in many different forms,and should not be construed as limited to the embodiments set forthherein. Rather, these embodiments are provided so that this disclosurewill be thorough and complete, and will fully convey the scope of theinvention to those skilled in the art. Like reference numerals refer tolike elements throughout.

It will be understood that when an element is referred to as being “on”another element, it can be directly on the other element or interveningelements may be present therebetween. In contrast, when an element isreferred to as being “directly on” another element, there are nointervening elements present. As used herein, the term “and/or” includesany and all combinations of one or more of the associated listed items.

It will be understood that, although the terms “first,” “second,”“third” etc. may be used herein to describe various elements,components, regions, domains, layers and/or sections, these elements,components, regions, domains, layers and/or sections should not belimited by these terms. These terms are only used to distinguish oneelement, component, region, domain, layer or section from anotherelement, component, region, domain, layer or section. Thus, “a firstelement,” “component,” “region,” “domain,” “layer” or “section”discussed below could be termed a second element, component, region,domain, layer or section without departing from the teachings herein.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting. As used herein, thesingular forms “a,” “an” and “the” are intended to include the pluralforms as well, unless the context clearly indicates otherwise. It willbe further understood that the terms “comprises” and/or “comprising,” or“includes” and/or “including” when used in this specification, specifythe presence of stated features, regions, integers, steps, operations,elements, and/or components, but do not preclude the presence oraddition of one or more other features, regions, integers, steps,operations, elements, components, and/or groups thereof.

Unless otherwise defined, all terms (including technical and scientificterms) used herein have the same meaning as commonly understood by oneof ordinary skill in the art to which this disclosure belongs. It willbe further understood that terms, such as those defined in commonly useddictionaries, should be interpreted as having a meaning that isconsistent with their meaning in the context of the relevant art and thepresent disclosure, and will not be interpreted in an idealized oroverly formal sense unless expressly so defined herein.

Exemplary embodiments are described herein with reference to crosssectional illustrations that are schematic illustrations of idealizedembodiments. As such, variations from the shapes of the illustrations asa result, for example, of manufacturing techniques and/or tolerances,are to be expected. Thus, embodiments described herein should not beconstrued as limited to the particular shapes of regions as illustratedherein but are to include deviations in shapes that result, for example,from manufacturing. For example, a region illustrated or described asflat may, typically, have rough and/or nonlinear features. Moreover,sharp angles that are illustrated may be rounded. Thus, the regionsillustrated in the figures are schematic in nature and their shapes arenot intended to illustrate the precise shape of a region and are notintended to limit the scope of the present claims.

The transition term “comprising” is inclusive of the transition terms“consisting of” and “consisting essentially of”.

All “inclusive” numerical ranges included herein are interchangeable andare inclusive of end points and all numerical values that lie betweenthe endpoints.

As used herein a “borehole” may be any type of borehole in an earthformation such as a well, including, but not limited to, a producingwell, a non-producing well, an experimental well, an exploratory well, awell for storage or sequestration, and the like. Boreholes may bevertical, horizontal, some angle between vertical and horizontal,diverted or non-diverted, and combinations thereof, for example avertical borehole with a non-vertical component.

The term “support member” refers to a device that supports theexpandable component and the tubing string. The “support member” mayalso function to protect, guard and/or shield the expandable componentfrom damage prior to its removal.

The term “expandable” as used in the “expandable component”, canencompass a variety of means by which the expansion can occur. Theexpansion can occur for example, through swelling, inflation viapressure, thermal expansion, and the like, or a combination thereof.Some expandable components may be actuated by hydraulic pressuretransmitted either through the tubing bore, annulus, or a control line.Other expandable components may be actuated via an electric linedeployed from the surface of the borehole. Furthermore, some expandablecomponents have been used that employ materials that respond to thesurrounding borehole fluids and borehole to form a seal.

Disclosed herein is an article for a sealing system that comprises aplurality of multilayered metallic domains that may comprise particles.In an exemplary embodiment, the article is a support member for asealing system that is used in underground boreholes. Each domaincomprises a metallic core that comprises a first metal. Disposed uponthe metallic core is a first layer that comprises a second metal. Thefirst layer may have disposed thereon an optional second layer thatcomprises a third metal. These multilayered metallic domains eachfunction as a galvanic cell when exposed to borehole fluids. In oneembodiment, these multilayered metallic domains are manufactured into asupport member for a sealing system that can be dissolved in acontrolled manner (when exposed to borehole fluids) to expose anexpandable component to the surrounding borehole fluids. The surroundingborehole fluids cause it to swell to form a seal that isolates oneportion of the borehole from another portion of the borehole.

Disclosed herein too is a method of manufacturing a support member thatcomprises the plurality of fused multilayered metallic domains that maycomprise sheets or lamina. The method comprises manufacturing a sheetfrom the first metal and disposing upon the opposing surfaces of thesheet a layer of a second metal. An optional third layer of metal maythen be disposed upon the opposing surfaces of the sheet. The sheet isthen cut into several smaller sheets, which are stacked on one anotherto form a stack. The stack is subjected to roll milling until it isreduced to a thickness that is a fraction of the original thickness ofthe stacked sheets. The first multilayered sheet is once again cut intoseveral sheets, which are stacked one on another and subjected torolling to produce a second multilayered sheet. The process of formingsheets, cutting and stacking them, and then rolling them is repeatedseveral times to produce a final sheet. The final sheet is then cut,stacked as before and forged into a desired shape (hereinafter termedthe “article”).

FIG. 1 is a depiction of an exemplary sealing system 100. The sealingsystem 100 is disposed around a tubing string 102 and comprises anexpandable component 104 and a support member 106. The support member106 supports the expandable component 104 during the introduction of thetubing string 102 into the reservoir and prevents the expandablecomponent 104 from degrading prior to the point at which it has to beutilized.

When the tubing string 102 has reached the point in the well at which itis to be used, the support member 106 is removed from the sealing system100 and the expandable component 104 is subjected to expansion toisolate one portion of the wellbore from another portion of thewellbore.

In order to effect the desired use of the expandable component 104, theremoval of the support member 106 has to be accomplished undercontrolled conditions. It is therefore desirable to have a supportmember 106 manufactured from a material that can be removed in acontrolled fashion so that the swelling of the expandable component 104can be brought about at the desired time to isolate one portion of thewellbore from another.

In an exemplary embodiment, the support member 106 is manufactured bystacking several multilayered metal sheets and repeatedly passing thesesheets through a roll mill. In each “pass” through the roll mill, thethickness of the stack is reduced to about 15 to about 30% of theoriginal thickness of the stack. A “pass” as defined herein is theprocess by which the original stack is reduced in thickness to about 15to about 30% of the original thickness of the stack. A pass may involvemultiple trips between the roll mills. In one embodiment, the thicknessof the stack is reduced to about 20 to about 28% of the originalthickness of the stack. In another embodiment, the thickness of thestack is reduced to about 22 to about 26% of the original thickness ofthe stack.

It is generally desirable to conduct a number of passes in the roll millso as to reduce the thickness of the original sheet to about ⅛ to about1/15 of its original thickness, specifically about 1/10 to about 1/13 ofits original thickness. The number of passes conducted during the rollmilling is about 2 to about 15, specifically about 3 to about 14 andmore specifically about 5 to about 10.

The rolling process may be a cold rolling process or a hot rollingprocess. Cold rolling processes are generally conducted below therecrystallization temperature of the metal, while hot rolling processesare generally conducted at a temperature above the recrystalizationtemperature of the metal. The recrystallization temperature inconsideration would be that for the metal or alloy having the highestrecrystallization temperature of all of the metals in the article. In anexemplary embodiment, the rolling process is a hot rolling process. Therolling process is generally conducted at a temperature of about 150 toabout 450° C. In an exemplary embodiment, the rolling process isgenerally conducted at a temperature of about 400 to about 437° C.

The process of forming multilayered sheets that are repeatedly rolled,cut and stacked produces a structure that comprises fine grainedstructure, including intermingled domains of a first and a second metaland their combinations. The structure of the domains in the article issimilar to that which would be obtained from the sintering of individualparticles each of which comprise a core and a plurality of layersdisposed upon this core to begin with. In other words, the productcomprises multistructured domains that contact one another. Themultilayered domains in the article contact one another and haveinterstices located between these domains. In one embodiment, thesedomains are fused to one another. The domains may have gradients incomposition between the first metal and the second metal. It may alsohave gradients in composition between the second metal and the thirdmetal as well as between the first metal and the third metal.

In one embodiment, the domains may alternatively also comprise afine-grained alloy rich in small intermetallic compound domains betweenthe first metal and the second metal, the first metal and the thirdmetal and the second metal and the third metal, with no layers betweenthese respective metals. The presence of a fine grained alloy results ina number of advantages. Fine grained alloys with concentration gradientsproduce effective galvanic cells. These structures produce animprovement in strength due to fine grain sizes and dense intergranularregions over other structures that contain layered domains.

FIG. 2 is a depiction of an exemplary microstructure for articlesmanufactured by the method described herein. The FIG. 2 depicts themicrostructure of an exemplary article 200 comprising the domains 202described herein. As may be seen in FIG. 2, each domain comprises thecore 204 that comprises the first metal, the first layer 206 thatcomprises the second metal, and the optional third layer 208 thatcomprises the third metal. As noted above, some domains may comprise afine grained alloy that comprises an intermetallic compound.

The core may have an average domain size of about 44 to about 1400micrometers. In an exemplary embodiment, the core may have an averagedomain size of about 63 to about 105 micrometers. The average domainsize is a radius of gyration.

The core with the first layer disposed thereon may have an averagedomain size of about 45.1 to about 1445 micrometers. In an exemplaryembodiment, the core with the first layer disposed thereon may have anaverage domain size of about 64.6 to about 108 micrometers.

The core with the first and the second layer disposed thereon may havean average domain size of about 45 to about 1600 micrometers. In anexemplary embodiment, the core with the first and the second layerdisposed thereon may have an average domain size of about 65 to about110 micrometers.

In one embodiment, in one method of manufacturing the support member, asheet comprising a first metal is coated on its opposing faces with alayer of a second metal. The sheet may have an original thickness ofabout 0.05 to about 0.20 centimeters, specifically about 0.08 to about0.18 centimeters, and more specifically about 0.1 to about 0.15centimeters. Each layer of second metal may have a thickness of about0.005 centimeters to about 0.02 centimeters, specifically about 0.003 toabout 0.015 centimeters, and more specifically about 0.001 centimetersto about 0.013 centimeters. An optional third metal layer may bedisposed on the opposing faces of the sheet to contact the second metallayer. The thickness of each third metal layer can be the same as thethickness of each second metal layer.

The first metal is generally present in an amount of about 60 to about95 weight percent (wt %) based on the total weight of the article. Anexemplary amount of the first metal is about 90 to about 92 wt % basedon the total weight of the article.

The second metal is generally present in an amount of about 5 to about40 wt %, based on the total weight of the article. An exemplary amountof the second metal is about 8 to about 10 wt % based on the totalweight of the article.

The third metal is generally present in an amount of about 0.0001 toabout 3 weight percent (wt %) based on the total weight of the article.An exemplary amount of the third metal is about 0.01 to about 0.1 wt %based on the total weight of the article.

In one embodiment, the layer of second metal may be disposed upon thesheet by techniques involving vapor deposition. Examples of suitabletechniques for disposing the second layer include chemical or physicalvapor deposition.

Chemical vapor deposition includes atmospheric chemical vapordeposition, low pressure chemical vapor deposition, ultrahigh vacuumchemical vapor deposition, aerosol assisted vapor deposition, directliquid injection chemical vapor deposition, microwave plasma assistedchemical vapor deposition, plasma enhanced chemical vapor deposition,atomic layer chemical vapor deposition, hot wire (hot filament) chemicalvapor deposition, metal organic chemical vapor deposition, combustionchemical vapor deposition, vapor phase epitaxy, rapid thermal chemicalvapor deposition, hybrid physical chemical vapor deposition, or acombination comprising at least one of the foregoing processes. Ifcombinations of the foregoing chemical vapor deposition processes areused, they may be employed simultaneously or sequentially.

Physical vapor deposition includes cathodic arc deposition, electronbeam physical vapor deposition, evaporative deposition, pulsed laserdeposition, sputter deposition or a combination comprising at least oneof the foregoing processes. If combinations of the foregoing physicalvapor deposition processes are used, they may be employed simultaneouslyor sequentially. Combinations of physical vapor deposition processes andchemical vapor deposition processes may also be used.

In another embodiment, the layer of second metal may be disposed uponthe sheet by techniques involving electroless plating, electroplating,dip-coating or cold spraying. Combinations of such methods can also beused to apply the second layer to the sheet.

The first metal and the second metal are selected such that they arecapable of forming a galvanic cell that can undergo corrosion in thepresence of borehole fluids. In other words, if the first metal formsthe anode of the galvanic cell, the second metal forms the cathode andvice versa. The first metal is different in composition from the secondmetal. The third metal is generally selected to control the rate ofcorrosion of the galvanic cell.

The first metal and the second metal may comprise transition metals,alkali metals, alkaline earth metals, or combinations thereof so long asthe first metal is not the same as the second metal. The first metal maycomprise aluminum, magnesium zinc, copper, iron, nickel, cobalt, or thelike, or a combination comprising at least one of the foregoing metals.The second metal may comprise aluminum, magnesium zinc, copper, iron,nickel, cobalt, or the like, or a combination comprising at least one ofthe foregoing metals so long as it is chemically different from thefirst metal. In one embodiment, the second metal is electrolyticallydifferent from the first metal

The third metal may comprise nickel, aluminum, magnesium zinc, copper,iron, cobalt, or the like, or a combination comprising at least one ofthe foregoing metals so long as it is chemically different from thefirst metal. In one embodiment, the third metal is chemically differentfrom the first metal and from the second metal. In another embodiment,the third metal is electrolytically different from the first metal andfrom the second metal.

In one exemplary embodiment, the first metal comprises aluminum, whilethe second metal comprises magnesium. The third metal may comprisenickel.

In another exemplary embodiment, the first metal comprises magnesium,while the second metal comprises aluminum. The third metal may comprisenickel.

In one embodiment, the sheet obtained after being subjected to areduction in thickness may be stacked and forged in a roll mill into ablank. The blank may then be extruded into a desired shape to form thedesired article. In an exemplary embodiment, the sheet obtained afterbeing subjected to a 2 to 5-pass reduction in thickness may be stackedand forged in a roll mill into a blank. The blank is then be extrudedinto a final desired shape.

In another embodiment, the sheet obtained after being subjected to areduction in thickness may be stacked and forged in a roll mill or in apress into round stock.

The process is advantageous in that it can be conducted rapidly whencompared with a comparative sintering process involving powders. It alsois desirable because it does not involve the formation and pressing ofmetal powders, which can sometimes be difficult. The process describedherein can be advantageously used for manufacturing sheet stock forrolled tube, stamped flat items, billet materials for balls, and thelike.

Support members manufactured by this method are advantageous becausetheir dissolution by borehole fluids can be controlled. This permits theswelling of the expandable component to be controlled as well.

The article described herein can be used as a support member for asealing system for underground wells from which oil and natural gas areextracted. In one method of using the support member, it is disposedupon an expandable component in a sealing system to support theexpandable component until it is desired to have the expandablecomponent expand and form a seal. When the tube string with the sealingsystem is moved underground during oil exploration, the borehole fluidsinteract with the support member setting up plurality of galvanic cellswithin the support member. The galvanic cells become operative causingthe eventual corrosion of the support member and the exposure of theexpandable component to the borehole fluids. The expandable componentexpands to causing sealing of one portion of the borehole from anotherportion of the well.

While the invention has been described in detail in connection with anumber of embodiments, the invention is not limited to such disclosedembodiments. Rather, the invention can be modified to incorporate anynumber of variations, alterations, substitutions or equivalentarrangements not heretofore described, but which are commensurate withthe scope of the invention. Additionally, while various embodiments ofthe invention have been described, it is to be understood that aspectsof the invention may include only some of the described embodiments.Accordingly, the invention is not to be seen as limited by the foregoingdescription, but is only limited by the scope of the appended claims.

What is claimed is:
 1. A method comprising: disposing upon a tubestring, a sealing system; the sealing system comprising: a expandablecomponent and a support member; wherein the support member comprises: aplurality of domains contacting one another; wherein the domainscomprise: a core comprising a first metal; and a first layer disposedupon the core; the first layer comprising a second metal; the firstmetal being chemically different the second metal; the first metal beingchemically different the second metal; wherein the domains comprise agradient in composition between the first metal and the second metal;wherein the core is in the form of a particle having a domain size of 44to 1400 micrometers, and wherein the plurality of domains haveinterstices between them; a second layer that is disposed upon the firstlayer, wherein the second layer comprises a third metal that isdifferent from the first metal and the second metal; where the secondmetal is present in an amount of 8 to 10 wt %, based on the total weightof the article; and where the third metal is nickel, aluminum, magnesiumzinc, copper, iron, cobalt, or a combination thereof; where the thirdmetal is present in an amount of 0.01 to 0.1 wt %, based on a totalweight of the article; introducing the tube string into a well;dissolving the support member; and swelling the expandable component. 2.The method of claim 1, wherein a rate of dissolution of the supportmember is controlled.
 3. The method of claim 1, wherein the first metalis aluminum, magnesium, zinc, copper, iron, nickel, cobalt, or acombination comprising at least one of the foregoing metals.
 4. Themethod of claim 1, wherein the second metal is aluminum, magnesium,zinc, copper, iron, nickel, cobalt, or a combination comprising at leastone of the foregoing metals.